SystemAir Topvex SoftCooler SR09, Topvex SoftCooler SR11, Topvex SoftCooler TR09-15 Operation And Maintenance

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Document in original language | 208766 · A002

Topvex SoftCooler SR09, SR11

Operation and Maintenance Instructions

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208766 | A002

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Contents

1 Warnings. .. .. ........ . . . ........ . . . ....... . . . ........ . . . .......1

2 Product description . . ....... . . . ....... . . . . ....... . . . . ....... . 1

2.1 Components .. . . . ........ . . . ........ . . ........ . . . ....1

2.2 Electrical cabinet . ........ . . . ........ . . ........ . . . ...2

3 Installing the unit.... . . ........ . . . ........ . . . ........ . . .......3

3.1 Installation.. . . . ........ . . . ....... . . . ........ . . . .......3

4 Refrigerant Control/Reporting ...... . . . . ....... . . . ....... . 3

5 Function Description ...... . . . . ....... . . . ....... . . . . ....... . . 4

5.1 General.... . . . . ....... . . . ....... . . . . ....... . . . . ....... . 4

5.2 Power control... . . . . ....... . . . . ....... . . . ....... . . . . .4

5.3 Power limitation. . . ....... . . . ........ . . . ....... . . . . ..4

6 Cooling flow chart . . . ........ . . . ........ . . . ........ . . ........ 5

6.1 The cooling function.. . . . ....... . . . . ....... . . . ......5

6.2 Components and function . . . ........ . . ........ . . .6

6.2.1 Compressor .. . ....... . . . . ....... . . . . .....6

6.2.2 Frequency converter (FC) .... . . . . .....6

6.2.3 Power controlling ...... . . . ....... . . . .. 10

6.2.4 Compressor protection .. ........ . . . . 10

6.2.5 Refrigerant . . . ........ . . ........ . . . ..... 10

6.2.6 Condenser/Evaporator ......... . . . .. 10

6.2.7 Drip tray . . ....... . . . ....... . . . . ....... . . . 10

7 Maintenance ........ . . ........ . . . ........ . . . ........ . . ...... 11

8 Alarms...... . . . ........ . . . ....... . . . ........ . . . ........ . . . .... 12

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Warnings

1 Warnings

The following admonitions will be presented in the different sections of the document.

Danger

• Make sure that the Mains supply to the unit is disconnected before performing any maintenance or electrical work!

• All electrical connections must be carried out by an authorized installer and in accordance with local rules and regulations.

• Operation in the refrigerant circuit and handling refrigerants must be performed by certified personnel.

Warning

• Beware of sharp edges during mounting and maintenance. Use protective clothing.

• Skin contact with the refrigerant must be avoided. Use protective equipment such as protective goggles, gloves and suitable clothing’s. Good ventilation must be arranged.

• If freezing injury a doctor must be seen.

• If skin contact the exposed part of the body must be carefully washed.

• If eye contact use eye wash or lukewarmed water and wash for 20 minutes, visit a doctor.

• The units electrical connection to the mains supply must be preceded by an all pole circuit breaker with a minimum 3 mm gap.

• This product is not intended to be used by children or people with reduced physical or mental ability or lack of experience and knowledge, if no instruction concerning the use has been given by the person responsible for their safety or that this person is supervising the operation. Children should be supervised so that they can not play with the product.

2 Product description

2.1 Components

Fig. 1 Basic components in left hand unit

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| Product description

Position Description

1. Compressor

Condenser coil

Evaporator coil

Filter drier with sight glas

Electronic expansion valve

Drip-tray with drain

Water seal

Cable grommet for external cabling

El. cabinet

10. Frequency converter

11.

Pressure/hot gas switches

12.

Measuring points refrigerant system high/low

2.2 Electrical cabinet

Fig. 2 Electrical cabinet

Position Description

Terminal block, mains supply

Circuit breaker (MCB) oil heater

Relays

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Installing the unit |

Position Description

Terminal block, internal/external connections

5. Frequency converter

DC choke

24V transformer

LCD display

3 Installing the unit

3.1 Installation

Fig. 3 Installation, left hand unit

Position Description

Supply

Exhaust

Outdoor

Extract

VAV pressure transmitter supply air (accessories)

2. VAV pressure transmitter extract air (accessories)

Damper and motor exhaust air (accessories)

Damper and motor outside air (accessories)

Sensor supply air

Topvex SoftCooler SR

4 Refrigerant Control/Reporting

Topvex SoftCooler SR comes pre-filled with refrigerants and belongs to the group "Piece units containing more than 3kg refrigerants per circuit". Before commissioning shall always a control report in respect of the installation be established by a cooling certified person. Leakage control with record keeping shall be done once per year. The installation of the Topvex SoftCooler SR is only duty to report if the property/enterprise where the installation occurs, all together after installation, has a total amount of refrigerants of 10 kg or more ("small Piece units" with refrigerants less than 3 kg, e.g. normal refrigerators/freezers does not includes). Reporting shall in occurring cases be done to major inspection authority (normally the municipal environmental office).

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Function Description

Different regulations can be valid in different countries. Check with your local government.

5 Function Description

HPS

CPR

HPS

CPR

Fig. 4 Left hand unit

Position Description

Extract air fan

Supply air fan

Temp. sensor supply air

Temp. sensor outdoor air

ETS Temp. sensor extract air

Controller E28

Rotor control

RM Rotor motor

Exchanger

Damper outdoor air (accessory)

DEH

Damper exhaust air (accessory)

FC Frequency converter

CPR Compressor

EV Evaporator

Condenser

HPS

Condenser pressure sensor

OT/ET Overheating/Max. temp switches

FGS/FGE Air filter pressure switches

5.1 General

Control unit E28 (UC) senses the temperature via the extract temperature sensor (ETS) and then keep the set extract temperature by sequence controlling the compressor (CPR), heat exchanger (HE) and hot water- /electrical heater (HWL/H, ELH). The temperature sensor in the supply air (SS) is min. and max. limiting the supply air temperature.

5.2 Power control

The compressor (CPR) are step-less controlled between, in the frequency converter (FC), set minimum and maximum frequency.

5.3 Power limitation

The programmable controller is continuously sensing the condensing pressure via the high pressure sensor (HPS) and gradually slows down the speed of the compressor (CPR), if the pressure exceeds the set limitation value. This is done to avoid a high pressure alarm.

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Cooling flow chart |

Note:

This instruction contains functions for the Topvex SoftCooler SR, for a complete description of functions see " SR 09,11, TR 09-15 Installation instruction".

6 Cooling flow chart

6.1 The cooling function

Extract air

Supply air

CRP Compressor

CCH

Crank case heater

DT Drop tray

EV Evaporator

Filter drier

FC Frequency converter

HGS

Hot gas switch

HPS Pressure sensor

Condenser coil

PSH

Pressure switch, high

PSL

Pressure switch, low

Sight glass

Pressure regulator

Vibration dampers

EXV

Expansion valve

High and low manometer connections

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| Cooling flow chart

The refrigerant is circulated in a completely closed system in the following order: Evaporator, Compressor, Condenser, and last expansion valve. The compressor keeps a low pressure in the evaporator, the refrigerants boiling point is thereby lowered and the incoming refrigerants from the expansion valve is vaporized (boiling) with absorption of heat as a result. The heat is taken from the supply air when passing the evaporator - supply air temperature is lowered. After a pressure increase in the compressor the refrigerant gas passing the condenser were the gas, thanks to the high pressure and thereby a high boiling point, is transformed into fluid through condensation and thereby heat emission. The heat is submitted to the exhaust air that passing the condenser. The heat has accordingly been transferred from supply air to exhaust air. After leaving the condenser in liquid state the refrigerant passes the expansion valve who controls the amount of refrigerants to the evaporator and thereby the cycle is completed.

6.2 Components and function

6.2.1 Compressor

The compressor in Topvex Soft Cooler is a high-efficiency, variable speed scroll compressor. It is designed especially for speed control and can not run without frequency converter. Speed and by that cooling capacity is regulated by changing the operating frequency, the maximum working range of the compressor is no less than 20 to 120 rps (revolutions per second). In the smaller unit sizes the maximum frequency is limited via a setting in the frequency converter. Controlling of the compressor is completely automatic according to the need of the premises and the signal comes via the control unit E28 to the frequency converter.

6.2.2 Frequency converter (FC)

The compressors frequency converter is located in the electrical cabinet. The programmable controller receives a control signal (0-10 V DC) corresponding to the current cooling load from the control unit E28 and then, via frequency converter, regulates the compressors speed according to the actual cooling load. The programmable controller has also a high pressure sensor (HPS) (4-20 mA) connected. This sensor continuously measuring the pressure in the cooling system. If the pressure exceeds the set value in the programmable controller the output frequency is reduced and thereby the compressors speed will be reduced so that the pressure will not rise to the level were the high pressure switch (PSH) on the high pressure side will trigger. The compressor is protected from fast start and stops by an restart delay function (3 minutes) in the programmable controller.

6.2.2.1 Integrated control, quick guide

FLSTDmCOMM is the CAREL solution for the management of a BLDC compressor via Power+ inverter.

The FLSTDmCOMM software installed on the PCOOEM+ programmable board features:

• Easy-to-use add-on to manage BLDC compressor by Power+ inverter via an analogue signal (0-5V/0-10V) or controlled via Modbus serial communication

• Full control of compressor working conditions, tested and approved by compressor manufacturers

• Use of electronic expansion valve manage via EVD EVO on-board (unipolar valve)

• No need of user interface (pGD1) when connecting to a BMS Modbus

• Energy saving and consequently cost savings, by integrated unit

• Improvement in system management, managed using a semi-graphic user interface (pGD1)

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Cooling flow chart |

6.2.2.1.1User interface

• Bell symbol

Display the list of active alarms

• Prg

Enter the main menu tree

• Esc

Return to the previous screen

• Up arrow

Scroll a list upwards or increase the value shown on the display

• Enter arrow

Enter the selected submenu or confirm the set value

• Down arrow

Scroll a list down wards or decrease the value shown on the display

6.2.2.1.2PGD1 Menu

From this mask you have access to the specific menu dedicated to the Power+ inverter parameters. Submenu masks are marked as follows:

• Configuration masks, with Pa01, Pa02, etc

• Regulation masks, with Pb01, Pb02, etc

• Custom configuration masks, with Pc01, Pc02, etc

From this mask you have access to the specific menu dedicated to the EVD Evo Parameters. Submenu masks are marked as follows:

• Configuration masks, with Ea01, Ea02, etc

• Regulation masks, with Eb01, Eb02, etc

• Manual cmd masks, with Ec01, Ec02, etc

From this mask you have access to the manual control of compressor and EVD valve for servicing; masks are indexes as Ma01 and Ma02.

From this mask you have access to the masks dedicated to the other parameters; all these masks are marked with Ot01, Ot02, etc.

From this mask you have access to the specific masks dedicated to the defrost option parameters; all these masks are marked with Df01, Df02, etc.

From this mask you have access to the specific masks dedicated to the BLDC compressor parameters; all these masks are marked with Co01, Co02, etc.

6.2.2.1.3Pa Menu: Power+ configuration

Reserved to Power + inverter configuration (e.g. "Compressor model"): generally there is no need to access to these masks for the purpose of this application program as all necessary setting has already been configured at the origin.

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| Cooling flow chart

This mask permits to select the compressor model controlled by Power+. Every change must be followed by the “Set defaults” command to send the new parameters values to the Power +.

For specific particular purpose, it is possible to save as “Custom” a special configuration made by changing some parameter of the characteristic ones of a compressor model. N.B.: the modification of the Power+ parameters has to be done by qualified personnel only, because it can result in a damage either for the compressor than for the Power+.

This masks allows to set the delay time before giving the alarm “Power+ offline” due to the absence of answers to the enquire of the PCOOEM+; the last row parameter permits to overcome ghost alarms at power up, e.g. when the “Safety Torque Off” digital input of the Power+ is used.

This mask permits to select the measuring unit of the speed shown in the mask “Sn11”

6.2.2.1.4Pb Menu: Power+ regulation

Reserved to Power + inverter regulation: there is no need to access to these masks for the purpose of this application program as all necessary setting has already been configured at the origin.

The parameters show the frequency limits of Power+ referred to the selected compressor.

It may be necessary to avoid particular frequencies in some systems due to mechanical resonance problems. Using the following parameters it is possible to fix the limits of the frequency area to be avoided for the frequency set point.

Switching frequency and its optional setting.

This masks defines the stopping mode with no deceleration ramp control, the disabling of the reverse speed (compressor damage!) and of the flying start (not possible with compressor).

The parameters of this mask permit the configuration of the output relay and of the PTC reading input (not used) with the relevant alarm delay time.

6.2.2.1.5Pc Menu: Power+ custom

Reserved to Power + inverter regulation: there is no need to access to these masks for the purpose of this application program as all necessary setting has already been configured at the origin.

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Cooling flow chart |

Configuration of BLDC motor type.

The base frequency is the frequency at which the maximum voltage is applied. The base voltage is the maximum voltage applied to the motor.

The rated current is the current at full load. The power factor is not used in the BLDC motor type. Maximum current is set at 100%.

Frequency step values of the start-up speed profile management: the function is disabled as the starting up is fully controlled by FLSTDmCOMM software installed on the PCOOEM +.

Acceleration values of the start-up speed profile management: the function is disabled as the starting up is fully controlled by FLSTDmCOMM software installed on the PCOOEM+.

Maintaining periods of speed prefixed values in the start-up speed profile management: the function is disabled as the starting up is fully controlled by FLSTDmCOMM software installed on the PCOOEM+.

Other parameters of the start-up speed profile management: the function is disabled as the starting up is fully controlled by FLSTDmCOMM software installed on the PCOOEM+.

Maximum value of deceleration ramp for the compressor in use.

These parameters optimize the initial start-up phase of the motor by adapting the V/f feature on the basis of the particular application, in order to improve performance at low speeds.

Parameters related to the motor electrical data.

Other parameters related to the motor electrical data (mathematical model of the motor).

PI regulation parameters to follow and maintain the specified speed value.

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| Cooling flow chart

These parameters optimize the initial start-up phase of the motor and the relative estimate of the position and the motor speed.

Special function settings to perform the direct writing of a specified parameter new value into Power+.

6.2.3 Power controlling

Control unit E28 in the air handling unit gives a demand signal ("Y3-cooling", 0-10V DC) in proportion to the current cooling demand in the extract air (or room). The signal is, via a relay (R1), connected to an analog input in the programmable controller. When the signal is connected (R1) actuates and the compressor starts and the speed is then controlled according to the demand signal between min. frequency (20 rps) and max. frequency (depends on unit size but still max. 120 rps).

6.2.4 Compressor protection

The compressor is protected by the following:

• Motor protection in the frequency converter (FC)

• High pressure switch in the high pressure side (PSH)

• Low pressure switch on the low pressure side (PSL)

• Hot gas thermostat on the hot gas tube (HGS)

• If any of the above protections is triggered control unit E28 will show Run Error P1–Cooler. Manual acknowledgment and reset must be done before the compressor can start again.

6.2.5 Refrigerant

The refrigerant is of type R410 A, the system comes pre-filled and tested at the factory. On top of the Topvex SoftCooler are the high- and low pressure side measuring points (tappings). Concerning the control and reporting of the refrigerant installation, see chapter 4.

6.2.6 Condenser/Evaporator

The condenser and evaporator coil is made of copper tubes with aluminium fins.

6.2.7 Drip tray

The drip tray is located under the evaporator/brine coil and collects the water condense that periodically occur during the cooling operation. The drip tray is made of stainless steel and has a 32 mm connection for connecting the drain pipe. The drip tray has an electrical heater to prevent the water condense from freezing.

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Maintenance

7 Maintenance

Caution

Maintenance of the Topvex SoftCooler is of great importance for the whole installations environmental influence, operating economy, durability, security and functions. Read the Warnings chapter 1 and Refrigerant Control/Reporting chapter 4 before doing any work on the SoftCooler unit.

Maintenance should be carried out two times a year, apart from general cleaning the following should be done:

1. Leakage control with registration (Legal requirements: at least 1 time a year)

Different regulations can be valid in different countries. Check with your local government.

2. General control.

When unit is running listen for abnormal sounds and vibrations. Inspect occurrence of oil leakage (can be a symptom on refrigerant leakage). Inspect occurrence of corrosion, fretting damages, loosen pipe suspensions.

3. Control of the cooling coil (evaporator coil) and condenser coil.

After a long time of use the coils can obtain a deposit that obstructs the heat transfer and airflow. Vacuum clean the coils carefully from the dirty side.

4. Control of the drip tray.

After a long time of use the drip tray and the drain can obtain a deposit that obstructs the drain of the condensation water. Clean the drip tray, drain, water seal and pipes from dirt and deposits.

5. Control of the air filter for the frequency converter.

The filter is located in the inspection door. After a long time of use the filter can be clogged so that the cooling airflow decreases and thereby causes a to high temperature for the frequency converter which results in operational disturbance. Loosen the filter from outside of the unit (snap locking of the cover), if the filter is dirty exchange it with a new (filter mat G5).

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| Alarms

8 Alarms

When an alarm is activated a message is displayed, the corresponding LED comes on and where necessary the alarm relay is activated.

The alarms can be divided into three categories:

• Serious unit alarms (these stop the compressor).

• Alarms that stop one or more functions of the system.

• Other alarms (signal only or “warnings”) that do not stop any function, but rather warn the user that certain thresholds have been exceeded, for example.

To monitor active alarms simply press the bell symbol and the display will show the name (or names, if there is more than one active alarm); to scroll the list, use the arrow up/down buttons.

To reset the alarms, display them and then press again. If the alarm condition no longer exists, the alarm is reset, otherwise it will be shown again.

Note:

With automatic reset, the system restarts operating in as, however the alarm LED and the corresponding warning string remain active until the bell symbol is pressed at least twice.

Table 1 Alarms

Alarm code

Display description

Reset

Delay Alarm

relay

Action

AL01

Clock board fault or not connected

Automatic

Immediate

Yes Just warning

signal

AL02

Extended memory error

Automatic

Immediate

Yes Just warning

signal

AL03

Max discharge pressure

Automatic

Immediate

Yes

Off compressor

AL04 Min. suction pressure Automatic

Immediate

Yes

Off compressor

AL05

Power+ offline

Automatic 30 sec Yes

Off compressor

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Alarms |

Alarms cont'd

Alarm code

Display description

Reset

Delay Alarm

relay

Action

AL06

Alarms Power+ n°1

0. No fault

1. Overcurrent

2. Motor overload

3. Overvoltage

4. Undervoltage

5. Drive overT

6. Drive underT

7. Overcurrent HW

8. Motor overtemp.

9. Reserved

10. CPU error

11. Param. default

12. DC bus ripple

13. Data comms fault

14. Drive thermistor

15. Autotune fault

16. Drive disabled

17. Motor phase

18. Fan fault

19. Speed fault

20. PFC failure

21. -

22. PFC undervoltage

23. STO Surevey

24. STO Survey

...

99. Unexpected inverter stop

Manual Immediate

Yes

Off compressor

AL07

EVD Evo Probes fault or disconnected

Automatic

Immediate

Yes

Off compressor

AL08 EVD Evo Low SuperHeat Automatic

Immediate

Yes

Just warning signal

AL09

EVD Evo Low evaporation temperature (LOP)

Automatic

Immediate

Yes Just warning

signal

AL10

EVD Evo High evaporation temperature (MOP)

Automatic

Immediate

Yes Just warning

signal

AL11 EVD Evo Low suction temperature Automatic

Immediate

Yes Just warning

signal

AL12

Compressor start failure After 5 time

in 1 hour became

10 sec Yes

Off compressor

AL13

Operating limit alarm (forced compressor closing due to exceeded operating limit)

Manual

60 sec Yes

Off compressor

AL14

Delta Pressure < than minimum required for lubrication

Automatic 60 sec Yes

Off compressor

AL15

Discharge max.temp. Manual Immediate

Yes

Off compressor

AL16

Temperature Probe U1 faulty or disconnected

Automatic 60 sec Yes Just warning

signal

AL17

Temperature Probe U2 faulty or disconnected

Automatic 60 sec Yes Just warning

signal

AL18

Temperature Probe U3 faulty or disconnected

Automatic 60 sec Yes Just warning

signal

AL19

Temperature Probe U4 faulty or disconnected

Automatic 60 sec Yes

Off compressor

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| Alarms

Alarms cont'd

Alarm code

Display description

Reset

Delay Alarm

relay

Action

AL20

Pressure Probe U5 faulty or disconnected

Automatic 60 sec Yes

Off compressor

AL21

Pressure Probe U6 faulty or disconnected

Automatic 60 sec Yes

Off compressor

AL22

Pressure Probe U7 faulty or disconnected

Automatic 60 sec Yes

Off compressor

AL23

Defrost ended by max time duration

Automatic Yes

Lock defrost

AL24

BMS offline (bit unchanged)

Automatic 20 se Yes

Depends on setting

AL25

Inverter model not compatible (Power+ only allowed)

Automatic 60 sec Yes

Off compressor

AL26

Start fail due to high DeltaP

Automatic 300 sec Yes

Off compressor

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Topvex SoftCooler SR09, SR11 · Operation and Maintenance Instructions · 208766 · en_GB · 18-03-2014 · A002

Systemair Sverige AB Industrivägen 3 SE-739 30 Skinnskatteberg, Sweden

Phone +46 222 440 00 Fax +46 222 440 99

www.systemair.com